Electrical junction assemblies for coupling electrical fixtures to suspending ceiling grids

ABSTRACT

A T-bar clip assembly that securely couples to T-bar structures that are used to construct suspended ceiling is disclosed. The T-bar assembly is configured to support one or more electrical fixtures and provide power feeds to the one or more electrical fixtures. The T-bar clip assembly comprises support brackets that secure to the T-bar structures and one or more housing structures that attach to a portion of the support brackets to form one or more corresponding junction box enclosures. The junction box enclosures provide the power feeds to the one or more electrical fixtures at locations that are substantially flush with support flanges of the T-bar structure, an outer surface of the removable ceiling tiles or both.

RELATED APPLICATION

This application is a Continuation application of the co-pendingapplication Ser. No. 11/077,690, filed Mar. 10, 2005, and titled“ELECTRICAL JUNCTION ASSEMBLIES FOR COUPLING ELECTRICAL FIXTURES TOSUSPENDING CEILING GRIDS,” which claims priority under 35 U.S.C. §119(e)from the Provisional Patent Application Ser. No. 60/552,464, filed onMar. 11, 2004, and titled “INTEGRATED TEE BAR CLIP AND ELECTRICAL SPLICECOMPARTMENT.” The co-pending application Ser. No. 11/077,690, filed Mar.10, 2005, and titled “ELECTRICAL JUNCTION ASSEMBLIES FOR COUPLINGELECTRICAL FIXTURES TO SUSPENDING CEILING GRIDS,” and Provisional PatentApplication Ser. No. 60/552,464, filed on Mar. 11, 2004, and titled“INTEGRATED TEE BAR CLIP AND ELECTRICAL SPLICE COMPARTMENT” are bothhereby incorporated by reference.

FIELD OF THE INVENTION

The invention relates to systems, devices for and methods of mountingand electrically coupling electrical fixtures to ceiling structures.More particularly, the present invention relates to systems, managementsystems, and devices for and methods of mounting and electricallycoupling fixtures to suspended ceiling grids.

BACKGROUND

Modem offices and schools often employ false, drop or suspendedceilings. A Suspended ceiling includes a grid of T-bar structures thatsupport removable ceiling tiles. The T-bar structures are typicallysecured to a stable building structure, such as an I-beam, a fixedceiling or a wall through wires that support the weight-bearing load ofthe T-bars and the removable ceiling tiles. The T-bar structures alsoprovide locations for securing mounting assemblies that cans be used tosuspend electrical fixtures.

Typically mounting assemblies that attach to T-bar structures are alsotypically secured to a stable building structure to help distribute theweight bearing of an electrical fixture suspended.

SUMMARY

The present invention is directed to T-bar clip assemblies and methods.A T-bar clip assembly, in accordance with the embodiments of theinvention, is configured to securely couple to a T-bar member with avertical support structure and horizontal support flanges that can alsobe described as having a substantially T-shaped cross section. T-barstructures are installed in an inverted fashion construct grids thatsupport removable ceilings that rest on the horizontal support flangeswith the vertical support structures extending upwards and that recedeinto the outer surface of the suspended ceiling.

A T-bar clip assembly is configured to support an electrical fixture,generally a light fixture, securely coupled to a T-bar structure. AT-bar clip assembly, in accordance with the embodiments of theinvention, includes at least one junction box that has an apertureconfigured to receive and secure to a piece of standard flexible orrigid conduit with power lines. The junction box also is configured toprovide at least one power feed directly out of the junction box toprovide power to the electrical fixture supported therefrom. Preferably,the power feed is flush with an outer surface of a removable ceilingtile, an outer edge of the support flanges of the T-bar structure, orboth, such that little no or insulating hardware is required above theremovable ceiling tile in order to properly install the electricalfixture.

In accordance with the embodiments of the invention, a T-bar clipcomprises support brackets that secure around a T-bar structure and oneor more housing structures. Preferably, the one or more housingstructures couple with at least one of the support brackets and togetherthey form a junction box enclosure that is recessed above the suspendedceiling grid. The junction box enclosure provides a one or morelocations for electrical connections and at least one power feedlocation out of the junction box that is substantially flush withsupport flanges of the T-bar structure.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A-B show schematic representations of a prior art T-bar clipassembly.

FIG. 2 shows a schematic representation of a prior art T-bar clipassembly with an adjustable bracket.

FIG. 3 is an exploded view of a T-bar clip assembly, in accordance withthe embodiments of the invention.

FIG. 4 shows a partial cross-sectional view of a T-bar clip assemblymounted flush with a surface of a suspended ceiling, in accordance withthe embodiments of the invention.

FIG. 5 is a schematic of power lines supported within a T-bar clipassembly, in accordance with the embodiments of the present invention.

FIG. 6 shows a perspective view of a T-bar clip assembly for use withtwo power feed locations, in accordance with the embodiments of thepresent invention.

FIG. 7 shows a perspective view of a T-bar clip assembly, in accordancewith further embodiments of the invention.

FIG. 8 shows a perspective view of a T-bar clip assembly, in accordancewith yet further embodiments of the invention.

FIG. 9 shows a perspective view of a T-bar clip assembly, in accordancewith yet further embodiments of the invention.

DETAILED DESCRIPTION

FIG. 1A shows side cross-sectional view of a prior art T-bar clipassembly 100 for mounting and suspending an electrical fixture (notshown) from a T-bar structure 106 that is used to form a T-bar grid thatsupports suspended ceiling tiles (not shown). The T-bar structure 106has a vertical support 16 and horizontal flanges 114 for supportingremovable ceiling tiles (not shown). The T-bar clip assembly 100includes a first mounting bracket 101 and second mounting bracket 103 athat are clamped together and around the T-bar structure 106. A boltfeature 104 is attached to at least one of the first mounting bracket101 and the second mounting bracket 103 therefrom.

In order to install the T-bar clip assembly 100, the first mountingbracket 101 is fitted up to the T-bar structure 106. The second mountingbracket 103 is moved in a direction indicated by the arrow 110 to clamparound the T-bar structure 106, such as shown in FIG. 1B, and aresecured together through a suitable clamping means 107. The firstmounting bracket 101 and the second mounting bracket 103 are thensecurely held in position around the T-bar structure 106 using a bolt orany other suitable securing feature (not shown). A wire or other feature105 can be attached to a top portion of the T-bar clip assembly 100. Thewire or other support feature 105 is used to couple the T-bar clipassembly 100 to a stable building structure, such as an I-beam or apermanent ceiling, and to support the weight-bearing load of anelectrical fixture attached to the T-bar clip assembly 100 through thebolt 104.

A T-bar clip assembly, such as the T-bar clip assembly 100 describedabove with reference to FIG. 1A and FIG. 1B, has several shortcomings.The T-bar clip assembly 100 is not adaptable for use withdifferent-sized T-bars, such as T-bars having different heights and/ordifferent widths. Further, the T-bar clip assembly 100 does not provideany features to support electrical connections 123 and 125 or wiring 121required to power the electrical fixture attached to and supported fromthe T-bar clip assembly. A power feed location can be provided byvertically mounting a junction box 111 to one of the mounting brackets101 and 103. However, typically only one junction box 111 can be mountedto the T-bar clip assembly 100. Further, the junction box 111 can not bemounted to the T-bar clip assembly 100 with the junction box 111 flushwith a surface of a suspended ceiling as indicated by the dotted line117. Accordingly, an insulator coupler or sleeve 119 must be installedto span the distance D1 between the junction box 111 and the surface ofthe suspended ceiling 117. Even when the T-bar clip assembly 100 isinstalled with the insulating coupler or sleeve 119, such installationof the T-bar clip assembly 100 may be not be acceptable or allowed bylocal or national electrical codes and regulations.

Bulvan et al. in U.S. Pat. No. 6,464,179 describes an improved T-barclip assembly 200, illustrated in FIG. 2, for securing to a T-barstructure 206 that can then be used for mounting and suspending anelectrical fixture from the T-bar structure 206, such as describedabove. The T-bar clip assembly 200 is more versatile than the T-bar clipassembly 100, described above, and is capable of securing to andclamping around a large range of sizes of T-bar. The T-bar clip assembly200 includes a first mounting bracket 201 and a second mounting bracket203 that secure around the T-bar structure 206. The first mountingbracket 201 and the second mounting bracket 203 are coupled toadjustable bracket 215 that is used to adjust the vertical position ofthe T-bar clip assembly 200. When the T-bar clip assembly 200 isinstalled, the adjustable bracket 215 is coupled to the T-bar clipassembly 200 through a bolt 204. A wire or other feature 205 can beattached to a top portion of the T-bar clip assembly 200 and support theweight-bearing load of an electrical fixture attached to the T-bar clipassembly 200. A power feed location can be provided by verticallymounting a junction box 211 to positions 213 and 217 on the adjustablebracket 215. Rigid or flexible conduit 221 with electrical lines 223 and225 can be fed into the junction box 211 for hardwiring the electricalfixture. As with the T-bar clip assembly 100, only one junction box 111can be mounted to the T-bar clip assembly 200 and because the junctionbox 211 cannot be mounted flush with a surface of a suspended ceiling,an insulator coupler or sleeve 219 must be installed to span thedistance between the junction box 211 and the surface of the suspendedceiling. Accordingly, there is a need for a T-bar clip assembly that canbe used for mounting and suspending an electrical fixture and thataddressees the aforementioned shortcomings.

FIG. 3 shows an exploded view of a T-bar clip assembly 300 in accordancewith the embodiments of the invention. The T-bar clip assembly 300includes support brackets 301 and 303 for securing around a T-barstructure 401 of a suspended ceiling grid to form a vertical housingsupport 350. The support bracket 301 can include a mounting aperture 316that mates with a mounting tab 314 on the support bracket 303 foraligning the support brackets 301 and 303 in a position around the T-barstructure 401. After the support brackets 301 and 303 are aligned, thesupport brackets 301 and 303 can be secured together to the positionaround the T-bar structure 401 using screws 321 and 322 that are screwedthrough mounting apertures 312 and 313. It will be clear to one skilledin the art that the support brackets 301 and 303 can be secured togetherand to the position around the T-bar structure 401 using any suitablesecuring means including, but not limited to, clips, nuts and bolts,geometric mating features and any combination thereof.

Still referring to FIG. 3, the support brackets 301 and 303 can includeflanges 311 and 331 that can be folded or bent down from a retractedposition, as shown with respect to the support bracket 303, to anextended position, as shown with respect to support bracket 301. Theflanges 311 and 331 preferably have receiving apertures 312 and 332 orpop-out structures (not shown) that can be removed to provide thereceiving apertures 312 and 332. The receiving apertures 312 and 332 arepreferably sized to couple to flexible or rigid conduit, such as shownin FIG. 6, which provide power lines to power an electrical fixture orfixtures (not shown) coupled to the T-bar clip assembly 300. The supportbrackets 301 and 303 can also include means for securing to a buildingsupport. For example, the support brackets 301 and 303 have wireapertures 319 and 320 for receiving a wire 402 that can be attached to abuilding support structure.

In accordance with a preferred embodiment of the invention, the T-barclip assembly 300 includes a housing structure 302 that is configured tocouple to the vertical housing support 350 and from a junction boxenclosure, such as shown in FIG. 6. In accordance with this embodimentof the invention, the flanges 311 form a top portion of the junction boxenclosure when the housing structure 302 is attached to the verticalhousing support 350. The housing structure 302 can be coupled to thevertical housing support 350 through one or more screws 321 andcorresponding mounting tabs 315 and/or any other suitable meansincluding, but not limited to, clips, nuts and bolts, geometric matingfeatures and any combination thereof. The housing structure 302 can alsoinclude a slotted feature 310 that receives a matched flange tab 318 ofthe flange 311. With the housing structure 302 attached to the verticalhousing support 350, at least one of the support brackets 301 and 303and the resultant junction box enclosure provides a location for splicesand electrical service connections to electrically couple the electricalfixture or fixture to the power lines and at least on power feedlocation from a bottom portion 309 of the housing structure 302.

At least one of the support brackets 301 and 303 preferably includes astud structure 308, or any other attachment means, for coupling to afixture hardware kit 339 and for supporting a light fixture. The fixturehardware kit 339 can include, for example, a canopy 304, 15 that coversany exposed portions of the T-bar clip assembly 300, a sleeve 307, fixreceiving power lines from the junction box enclosure, and a bushing 305with a support wire 306 that attaches to the stud structure 308 or otherattachment means for supporting the weight bearing load of the lightfixture.

FIG. 4 shows a partial cross-sectional view of an installed T-bar clipassembly 400, in accordance with the embodiments of the invention. Thehousing structure 302 is coupled to the support bracket 301 that isattached to the T-bar structure 401 and is preferably attached to theT-bar structure 401 such that the support bracket 301 is verticallypositioned and substantially parallel with the vertical support 405 ofthe T-bar structure 401. The housing structure 302 and the supportbracket 301 form the junction box enclosure 411 that provides at leastone power feed 409 with power lines to power an electrical fixture, suchas described in detail above. Preferably, the power feed 409 exits thejunction box enclosure 411 at a location at a bottom portion 413 of thejunction box enclosure 411, wherein the location is substantially evenwith or flush with the outer surface 415 of a removable ceiling tile409, a horizontal support flange 407 of the T-bar structure 401 or both.As described above, the T-bar clip assembly 400 is configured to coupleto a fixture hardware kit that can include a canopy structure 304, forcovering exposed portions of the T-bar clip assembly 400, and a sleevestructure 307, for receiving power lines from the power feed 409,exiting the bottom portion 413 of the junction box enclosure 411.

FIG. 5 shows a perspective view 500 of a housing structure 303, inaccordance with the embodiments of the invention. Like-numbered elementsin FIGS. 5 and 3 refer to similar elements. The housing structure 303includes power feed support flanges 309 and 309′ to support a power feedline 409 with power wires 421 and 423 contained therein. The power feedline 409 can be supported by the power feed support flanges 309 and 309′with a grommet structure 417, a knot or any other structure that helpsprevent the power feed line 409 from being pulled through the supportflanges 309 and 309′.

FIG. 6 shows a perspective view of a T-bar clip assembly 600 coupled toa T-bar clip structure 401, in accordance with further embodiments ofthe invention. Again, like-numbered elements in FIGS. 6 and 3 refer tosimilar elements. The T-bar clip assembly 600 includes a first housingstructure 302 and a second housing structure 302′ that are configured tobe coupled to a vertical housing support 350. The vertical housingsupport 350 can be formed form a first housing support bracket 301 and asecond housing support bracket 303, wherein the first housing structure302 and the first housing support bracket 301 form a first junction boxenclosure 411 and the second housing structure 302′ and the secondhousing support bracket 303 form a second junction box enclosure 411′.Each of the first junction box enclosure 411 and the second junction boxenclosure 411′ is configured to couple to conduits 403 and 403′ throughtop portions 311 and 311′ of the junction box enclosures 411 and 411′,respectively. As described above the top portions 311 and 311′ of thejunction box enclosures 411 and 411′ can be formed from flangestructures that extend outward from the first housing support structure301 and the second housing support structure 303, respectively. Each ofthe junction box enclosures 411 and 411′ provide power-feed locationthrough bottom portions of the junction box enclosure 411 and 411′, asdescribed above. Preferably, the power feed locations are even with orflush with an outer surface of a removable ceiling tile, a horizontalsupport flange 407 of the T-bar structure 401 or both. The T-bar clipassembly 600 is configured to couple to multiple electrical fixturesthrough an electrical fixture hardware kit 339′ that can include acanopy 304, for covering exposed portions of the T-bar clip assembly600, sleeves 307 and 307′, for receiving power lines from power feedsexiting the junction box enclosures 411 and 411′, and a bushingstructure 305 with a support wire 306 for coupling to the T-bar clipassembly 600 and supporting the weight-bearing load of electricalfixtures attached thereto. Also, the T-bar clip assembly 600 can becoupled to a wire support 402 that is attached to a building structure.

FIG. 7 shows a T-bar clip assembly 700, in accordance with furtherembodiments of the invention. The T-bar clip assembly 700, includes afirst housing support structure 701 and a second housing supportstructure 703 that are configured to secure around a T-bar structure(not shown) and provide a vertical housing support structure 750, suchas described above. The T-bar clip assembly 700 also includes a housingstructure 702 configured to couple to the vertical housing supportstructure 750 through any suitable means and form a junction boxenclosure. The junction box enclosure is configured for providing one ormore power feeds that exit the junction box enclosure at a position thatis even with or flush with a suspended ceiling (i.e. a T-bar structureand/or removable ceiling tile.) A housing structure 702 preferablyincludes a top portion 711 with an aperture 712 configured to couple toconduit, which provides power lines into the junction box enclosure.

FIG. 8 shows a T-bar clip 800, in accordance with yet furtherembodiments of the invention. The T-bar clip assembly 800 includes afirst housing support structure 801 and a second housing supportstructure 803 that are configured to secure around a T-bar structure(not shown) and provide a vertical housing support structure 850, suchas described above. The T-bar clip assembly 800 also includes a housingplate 802 configured to attach to an integral housing structure 807 ofthe first housing support structure 801 and form a junction boxenclosure. The junction box enclosure is configured for providing one ormore power feeds that exit the junction box enclosure at a location thatis even with or flush with a suspended ceiling. The integral housingstructure 807 preferably includes a top portion 811 with an aperture 812configured to couple to a conduit that provides power lines into thejunction box enclosure.

FIG. 9 shows a T-bar clip assembly 900, in accordance with still furtherembodiments of the invention. Again, like-numbered elements in FIGS. 8and 3 refer to similar elements. The T-bar clip assembly 900, includeshousing support structure 901 and a T-bar clip feature 906 configured tosecure around the T-bar structure 401. The housing support structure 901is coupled to the T-bar clip feature 906 to form a vertical housingsupport structure. The housing support structure 901 is coupled to theT-bar clip feature 906 through a screw 924 or any other suitableattachment feature including, but not limited to, clips, nuts and bolts,other geometric mating features and any combination thereof. The T-barclip assembly 900 also includes a housing structure 902 configured tocouple to the housing support structure 901 and form a junction boxenclosure. The junction box enclosure is configured to provide one ormore power feeds even with or flush with a suspended ceiling. Thehousing support structure 901 can include a flange 911 that forms a topportion of the junction box enclosure with the housing structure 902coupled to the housing support structure 901. The flange 911 can includean aperture 912 configured to couple to the conduit that provides powerlines into the junction box enclosure.

The present invention has been described in terms of specificembodiments incorporating details to facilitate the understanding of theprinciples of construction and operation of the invention. As such,references, herein, to specific embodiments and details thereof are notintended to limit the scope of the claims appended hereto. It will beapparent to those skilled in the art that modifications can be made inthe embodiment chosen for illustration without departing from the spiritand scope of the invention.

1. A clip assembly comprising: a) support brackets for securing around aT-bar structure of a suspended ceiling grid; and b) a housing structurefor coupling to at least one of the support brackets and thereby forminga recessed junction box enclosure located above the suspended ceilinggrid for supporting electrical connections and providing a power feedswherein a bottom portion of the recessed junction box enclosure formedis substantially flush with support flanges of the T-bar structure. 2.The clip assembly of claim 1, wherein the housing structure includes areceiving aperture for coupling to a conduit.
 3. The clip assembly ofclaim 1, wherein the housing structure includes power feed supportflanges to support power feed wires.
 4. The clip assembly of claim 1,wherein the housing structure includes mounting tabs for coupling to atleast one of the support brackets.
 5. The clip assembly of claim 1,wherein the at least one of the support brackets comprises a flange tabthat forms a top portion of the junction box enclosure.
 6. The clipassembly of claim 5, wherein the flange tab includes a receivingaperture for coupling to a conduit.
 7. The clip assembly of claim 1,wherein at least one of the bracket structures includes a canopy studfor securing to an electrical fixture.
 8. The clip assembly of claim 1,wherein the support brackets include means for securing to a buildingsupport.
 9. An electrical junction assembly comprising: a) a verticalhousing support that securely couples to a T-bar structure of asuspended ceiling grid; and c) a housing structure configured to attachto the vertical housing support and form a junction box enclosure with abottom portion that has a power feed outlet substantially even withsupport flanges of the T-bar structure.
 10. The electrical junctionassembly of claim 9, wherein the vertical housing support is formed froma first support bracket and a second support bracket that secure aroundthe T-bar structure of the suspended ceiling grid.
 11. The electricaljunction assembly of claim 9, wherein the housing structure includes areceiving aperture for coupling to conduit.
 12. The electrical junctionassembly of claim 9, wherein the housing structure includes power feedsupport flanges to support power feed wires.
 13. The electrical junctionassembly of claim 9, wherein the housing structure includes mountingtabs for coupling to the vertical housing support.
 14. The electricaljunction assembly of claim 9, wherein the vertical housing supportcomprises a flange tab that forms a top portion of the junction boxenclosure.
 15. The electrical junction assembly of claim 14, wherein theflange tab includes receiving aperture for coupling to conduit.
 16. Theelectrical junction assembly of claim 9, wherein the vertical housingsupport includes means for attaching and supporting an electricalfixture.
 17. The electrical junction assembly of claim 9, wherein thevertical housing support includes means for securing a building support.18. A method of making a T-bar clip assembly for securing to a T-barstructure comprising a vertical support structure and horizontal supportflanges, the method comprising; a) forming a support structureconfigured to secure to a T-bar structure and form a vertical housingsupport that is parallel with the vertical support structure of theT-bar structure; and b) forming a housing structure configured tosecurely couple to the vertical housing support and form a junction boxenclosure that provides one or more power feeds below the verticalsupport structure and substantially flush with the horizontal supportflanges.
 19. The method of claim 18, wherein forming the supportstructure comprises forming a first support bracket and a second supportbracket that secure around a cross-section of the T-bar structure. 20.The method of claim 18, wherein forming a housing structure comprisescutting a receiving aperture for coupling to a conduit.
 21. The methodof claim 18, wherein forming a support structure comprises cutting aflange tab that can be adjusted to form a portion of the junction boxenclosure.